Hybrid truck bed liner

ABSTRACT

An apparatus to protect a wear surface of a vehicle, the apparatus having a resilient layer and a fabric layer bonded to the resilient layer, wherein the fabric layer is configured to be bonded to the wear surface of the vehicle. Other embodiments include an apparatus to protect a vehicle wear surface, the apparatus having a plurality of liner sections, wherein each liner section is configured to cover and be adhered to a portion of the vehicle wear surface, each of the plurality of liner sections including a resilient layer bonded to a fabric layer, wherein the fabric layer is configured to be adhered to the vehicle wear surface. Other embodiments include a method to protect a vehicle wear surface, the method including covering the vehicle wear surface with a plurality of liner sections wherein each liner section has a resilient layer and a fabric layer, adhering the fabric layer of each liner section to the vehicle wear surface, and joining adjacent liner sections together.

CROSS-REFERENCE TO RELATED APPLICATION

This application, pursuant to 35 U.S.C. § 120, claims benefit to U.S.patent application Ser. No. 11/545,316, filed Oct. 10, 2006,incorporated by reference in its entirety.

BACKGROUND OF INVENTION

1. Field of the Invention

Embodiments disclosed herein relate generally to liners for pickup truckbeds, sport utility vehicles, vans, and trailers. Specifically,embodiments disclosed herein relate to a hybrid truck bed liner,encompassing benefits of both drop-in and spray-in liners.

2. Background

Bed liners are commonly used to protect the bed or cargo area of avehicle from detrimental physical impacts, surface abrasion, orcorrosion due to reactive chemicals. Liner products have been used inSUV or van cargo areas, cabinets (such as for the storage compartmentsof a fire engine or a boat), and, most commonly, in the beds of pickuptrucks.

Liners for cargo areas may include carpeting or other textiles, such asa trunk liner. For example, U.S. Pat. No. 5,721,177 discloses nonwovenmoldable composites for use as a trunk liner. The nonwoven composite maybe made by admixing and encapsulating reinforcement fibers with athermoplastic resin formed from melted and compressed thermoplasticfibers having a melting point less than the melting point of thereinforcement fibers. A decorative or reinforcing covering material,such as carpets, cloths, and the like, may also be attached to thenonwoven composite. Other examples of textiles that may be used to linea trunk or cargo area are disclosed in U.S. Pat. Nos. 4,818,586,5,436,064, 5,492,580, and 5,600,974. Many of these textiles, however, donot have the impact or chemical resistance, such as may be obtained witha rubberized non-skid surface, desired for use in the beds of pickuptrucks.

Liners commonly used in pickup trucks generally include “spray-in” and“drop-in” liners. Drop-in liners are a pre-formed rigid plasticcomponent that form-fits the bed to be protected. Drop-in liners aredescribed in, for example, U.S. Pat. Nos. 6,692,054, 6,237,980,4,575,146, 4,540,214, 4,181,349, RE32,198, and others. Spray-in linersare formed by spraying a polymer coating into the truck bed or vehiclecargo area and then curing the polymer coating. Spray-in liners aredescribed in, for example, U.S. Pat. Nos. 6,613,389, 6,533,189, and6,126,999, among others.

Although serving to protect the cargo areas covered, the above describedliners also have drawbacks. For example, spray-in liners generallyrequire professional installation including an initial scuffing orsand-blasting of the surface prior to installation to ensure theformation of a permanent bond between the liner and the truck bed. Othernegative aspects of spray-in liners may include overspray, health issues(such as from the use of isocyanates), poor consistency of the finishedproduct, masking of the truck bed, the need for complex equipment, andthe overall appearance of the final product. Additionally, thepermanence of the installation means that if any damage, fading(“chalking”), or staining of the liner occurs, an expensive linerremoval process may be necessary to restore the liner's appearance.

Drop-in liners also have various drawbacks. For example, drop-in linersoften require the drilling of holes in the body of the bed forinstallation, thus exposing portions of bare metal in the bed andpossibly imparting rust-initiating stress in the metal. Further, drop-inliners typically have slick surfaces, allowing unwanted sliding of cargoin the bed. Furthermore, water, salt, sand, and grit may get under thebed liner, causing damage (e.g., rust), and vibration of a poor-fittingdrop-in liner may also damage the bed of the truck. Moreover, the bulkydrop-in liners, tailored for each pick-up truck model, are difficult andcostly for manufacturers and retailers to store and ship. Additionally,among other drawbacks, drop-in liners may crack or warp. Drop-in liners,due to their removable nature, have also reportedly blown out of thebeds of pickup trucks at high driving and wind speeds.

Several of these drawbacks are acknowledged in previous attempts tominimize their impact. For example, bed mats have been proposed tominimize the movement of cargo on the liner during use, such asdisclosed in U.S. Pat. Nos. 5,988,723 and 5,695,235, or to minimize therubbing between the liner and the cargo bed, such as disclosed in U.S.Pat. No. 6,431,629. Multi-piece or flexible bed liners have beenproposed to minimize the storage and shipping of bed liners, such as inU.S. Pat. Nos. 5,806,909, 4,986,590 and U.S. Patent ApplicationPublication No. 20020149223. And, removable bed liners, such as linersmagnetically attached to the truck bed, or liners temporarily attachedusing suction cups, are disclosed in U.S. Pat. Nos. 5,806,909 and4,279,439, respectively. A composite bed liner formed from spray-in anddrop-in components is disclosed in U.S. Pat. Nos. 7,093,875 and6,840,559. However, each of these solutions may result in additionalinstallation cost, may be ineffective at preventing impact or corrosivedamage, or may itself result in further damage to the bed.

Furthermore, the touted benefits of the various liners are often used topersuade the end-user (customer) in their choice of bed liners. Forexample, drop-in liners, in comparison to spray-in liners, betterdistribute the force of impacts, are better at protecting the surfacefrom dents, are less expensive than spray-in liners, may be removed, andmay be installed by a vehicle owner after market. Spray in liners, incomparison to drop-in liners, seal the bed surface, preventing water,salt, sand, and grit from getting between the liner and the surface,causing damage. Thus, there is a desire in the industry for a bed linerthat encompasses the benefits of both drop-in and spray-in liners.

SUMMARY OF INVENTION

In one aspect, embodiments disclosed herein relate to an apparatus toprotect a wear surface of a vehicle. The apparatus may include aresilient layer and a fabric layer bonded to the resilient layer,wherein the fabric layer is configured to be bonded to the wear surfaceof the vehicle.

In another aspect, embodiments disclosed herein relate to an apparatusto protect a vehicle wear surface. The apparatus may include a pluralityof liner sections, wherein each liner section is configured to cover andbe adhered to a portion of the vehicle wear surface, each of theplurality of liner sections including a resilient layer bonded to afabric layer, wherein the fabric layer is configured to be adhered tothe vehicle wear surface.

In another aspect, embodiments disclosed herein relate to a method toprotect a vehicle wear surface. The method may include covering thevehicle wear surface with a plurality of liner sections, wherein eachliner section comprises a resilient layer and a fabric layer, adheringthe fabric layer of each liner section to the vehicle wear surface, andjoining adjacent liner sections together.

Other aspects and advantages of the invention will be apparent from thefollowing description and the appended claims.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 and FIG. 1A are schematic drawings of a liner formed inaccordance with embodiments disclosed herein.

FIGS. 2A-2E present schematic drawings of a truck bed (2A) andembodiments of a bed liner described herein (2B-2E).

FIGS. 3A and 3B schematically present a side view (3A) and front view(3B) of embodiments of a liner described herein, where the liner mayprotect the surface of a cavity, such as a cabinet.

FIGS. 4-6 schematically present various multi-component liners formed inaccordance with embodiments disclosed herein.

FIGS. 7A and 7B schematically illustrate embodiments of overlyingportions of a multi-component liner formed in accordance withembodiments disclosed herein.

FIGS. 8A and 8B schematically illustrate liners having graphics ordecorative textures according to embodiments disclosed herein.

DETAILED DESCRIPTION

In one aspect, embodiments disclosed herein relate to a composite lineruseful for protecting a substrate from damage. In some aspects, theliners disclosed herein may include a fabric layer disposed on or withina resilient layer, and optionally a layer of flexible or rigid foam. Thefabric layer, in some embodiments, may serve as a reinforcing layer ormay serve as a bridge for bonding the resilient layer to a substrate. Inother aspects, embodiments disclosed herein may include a liner that isremovably bonded to a substrate.

Referring now to FIG. 1, one embodiment of the liner described herein isillustrated. A liner 10 may be disposed on or adhered to the surface ofa substrate 12, where the surface and integrity of substrate 12 aredesired to be protected from damaging chemicals and/or impacts. Liner 10may include a fabric layer 14 and a resilient layer 16. In variousembodiments, liner 10 may include one or more fabric layers 14 and oneor more resilient layers 16. One such embodiment is illustrated in FIG.1A, having a resilient layer 16, a first fabric layer 14A bonded to theresilient layer 16, and a second fabric layer 14B bonded to the firstfabric layer 14A and configured to be bonded to the substrate 12.

Substrate 12 may include various metallic, mineral, composite, alloy,fiberglass, cellulosic (wood), or polymeric surfaces that are desired tobe protected from deleterious chemical and/or physical attack. Forexample, in some embodiments, substrate 12 may include iron, steel,aluminum, and other metals, such as is commonly used in the manufactureof trucks, boats, trailers, SUVs, and RVs. In other embodiments,substrate 12 may include fiberglass, carbon-fiber composites, polymersand wood species.

As described briefly above, embodiments of the liner described hereininclude various components and methods for attachment, and in someembodiments may be easily removed from a substrate. Each of these isdescribed in more detail below, followed by additional embodiments ofthe liner.

Resilient Layer

In various embodiments of the liner described herein, chemical,abrasion, and/or impact resistance is desired. The resilient layer, insome embodiments, may provide impact and abrasion resistance. In otherembodiments, the resilient layer may provide chemical resistance. Invarious embodiments, the resilient layer may provide impact, abrasion,and chemical resistance.

In various embodiments, the resilient layer may be formed from aurethane-based rubber. In some embodiments, the urethane based rubbermay be formed using a resin blend of polyurethane and polyurea activatedwith an isocyanate.

In other embodiments, the urethane rubber may be formed by providing awater curable liquid rubber urethane and a water-based acrylic. Therubber based urethane may be a moisture-cured, liquid appliedpolyurethane. The urethane may be either aliphatic or aromatic, and maybe based on aliphatic isocyanates, aromatic isocyanates, oraromatic-aliphatic isocyanates, and combinations thereof. The rubberbased urethane may be selected from any one of the group consisting ofnatural rubbers, recycled rubbers, styrene butadiene, polybutadiene,polyisoprene, ethylene propylene, chloroprene, acrylonitrile-butadiene,ethylene-propylene, chloroprene, acrylonitrile-butadiene, andethylene-propylenediene monomer, isopreneisobutylene.

In some embodiments, the resilient layer may be heat vulcanized,pressure-cured, post-cured, room-temperature cured or vulcanized, andcombinations thereof. Those of ordinary skill in the art will recognizethat other forms of post-formation treatment may also be possible.

Any water-based acrylic may also be used with the present invention. Thebase polymer for this dispersion may be a carboxyl-functional acrylicresin, which may be neutralized with amine to form an anionicdispersion. The dispersion may further comprise acrylic resin,triethylamine, xylene, and propoxyethanol, in varying weight ranges.

In other embodiments, the resilient layer may be formed from a liquidsprayable epoxy composition comprising a liquid epoxy resin, aneffective reinforcing amount of fiber, an elastomeric component, and anamine containing epoxy curing agent capable of curing the composition attemperatures equal to or greater than 40° F. wherein the cured productis light stable and has a hardness on the Shore D scale. In otherembodiments, the resilient layer may be formed in situ as a curedproduct by spraying, brushing, or rolling the epoxy composition onto thesubstrate, such as the truck bed, curing and forming the product on thesubstrate at a temperature of at least 40° F. The ratio of epoxyreactive groups to amine reactive groups may range from 0.9:1.0 to1.1:1.0.

In other embodiments, the resilient layer may be formed from aqueousdispersions of urethane polymers and vinyl polymers (e.g., acrylics)that provide water-based coating compositions with good adhesionfollowing humidity exposure. The dispersion is predominately urethane,and the polyurethane is made from a first and a second polyisocyanate,the first polyisocyanate having at least one open carbon chain greaterthan six carbon atoms in length between two isocyanate groups,preferably at least eight carbon atoms in length. The vinyl monomers arepolymerized in the presence of the aqueously dispersed polyurethane.

In other embodiments, the resilient layer may include any type ofresilient material, such compounds as disclosed in U.S. Pat. Nos.6,533,189, 6,126,999, 5,739,194, 5,436,112, 5,084,521, 4,282,123, and4,692,382, among others. In other embodiments, the resilient layer mayinclude an acrylate polymer, a urethane polymer, a heat vulcanizedrubber, a vinyl rubber, a vinyl polymer, a polyolefin, a urethanerubber, a vulcanized urethane, or combinations thereof.

In other embodiments, the resilient layer may include two or more layersadhered to one another. For example, the resilient layer may include acoating system which forms a highly abrasion resistant, chemicalresistant, impact resistant protective finish for a substrate. Theoutermost or surface coating layer may be a highly cross-linked hardpolymer, which may be adhered to an underlying base coating layer of acompatible softer polymer. The outer hard polymer preferably may includea highly crosslinked acrylic polymer, while the underlying softerpolymer may include a crosslinked urethane polymer.

In other embodiments, a resilient layer may be formed from one or moreof the compounds and coatings described above. In other embodiments, theresilient layer may be formed from the coating systems disclosed in U.S.Pat. Nos. 5,114,783 and 5,254,395.

In some embodiments, the resilient layer may have an average thicknessin the range from 0.1 mm to 50 mm (0.004 inches to 2 inches). In otherembodiments, the resilient layer may have an average thickness in therange from 1 mm to 38 mm (0.040 inches to 1.5 inches); from 2.5 mm to31.75 mm (0.1 inches to 1.25 inches) in other embodiments; and from 12mm to 25 mm (0.5 inches to 1.0 inches) in yet other embodiments.

The preferred texture of the exposed surface of the liner may dependupon the intended use of the surface. In some embodiments, the resilientlayer may include an outer surface that is rough in texture. In otherembodiments, the resilient layer may include an outer surface that issmooth in texture. In some embodiments, the resilient layer may includean outer surface that is substantially flat. In other embodiments, theresilient layer may include an outer surface that is ribbed orcorrugated, such as to mate with the raised portions of a truck bed. Invarious embodiments, the ribbed surface may provide additional strengthto the liner or may facilitate drainage from the liner. In someembodiments, the resilient layer may be flexible. In other embodiments,the resilient layer may be rigid. In other embodiments, the resilientlayer may include an outer surface that includes graphics or decorativetexturing, such as company logos, animal skins, and other decorativepatterns and textures, for example.

The hardness of the resilient layer, in some embodiments, may be suchthat it aids in preventing objects from sliding on its surface. In otherembodiments, the hardness of the resilient layer may be such that itabsorbs energy when struck with an impact, such as to prevent thesubstrate from being deformed.

In other embodiments, the resilient layer provides a surface that isresistant to corrosive or reactive chemicals. In this manner, theresilient layer may protect the substrate by providing a non-reactive ornon-permeable buffer between a corrosive chemical and the substrate.

In some embodiments, the resilient layer may have a durometer hardnessof at least 10 on a Shore A scale. In other embodiments, the resilientlayer may have a durometer hardness of at least 30 on a Shore D scale.In other embodiments, the resilient layer may have a durometer hardnessfrom about 10 on a Shore A scale to about 80 on a Shore D scale.

Fabric Layer

Embodiments of the liner disclosed herein may include one or more fabriclayers. The fabric layers may serve as a strength reinforcement of theresilient layer, may serve as an aid for bonding the resilient layer toa substrate surface, or a combination thereof. The fabric layer, invarious embodiments, may include woven or non-woven, natural orsynthetic, components or fibers. The fabric layer may provide enhanceddimensional stability to the liner structure, and may also providesurface area for the application of direct glue-down adhesives.

In other embodiments, the fabric layer may serve as a bridge for theadhesion of the liner to a substrate surface. In other embodiments, thefabric layer may serve as a bridge for the adhesion of the liner to aflexible foam intermediate the liner and the substrate surface. Such abridge may be necessary where adhesion of the resilient layer to thesubstrate surface would be impracticable, such as where the resilientlayer contains a mold-release agent limiting the bonding that may occurbetween the resilient layer and a substrate surface, for example.

In some embodiments, the resilient layer may be disposed on or adheredto the fabric layer. In other embodiments, the resilient layer may bevulcanized to the fabric layer. In other embodiments, the fabric layermay be disposed partially or wholly within the resilient layer. Forexample, in some embodiments where a fabric layer is disposed whollywithin the resilient layer, that fabric layer may reinforce the strengthof the resilient layer. In other embodiments, where a fabric layer isdisposed partially within the resilient layer, the fabric layer may actas a bridge for the adhesion of the liner to a substrate surface.

Fabrics and fibers suitable for making the woven or non-woven fabriclayer may include any natural or synthetic cellulosic fibers includingcotton, abaca, kenaf, sabai grass, flax, esparto grass, straw, jutehemp, bagasse, milkweed floss fibers, and pineapple leaf fibers; andwoody fibers. In other embodiments, the fabric layer may includesynthetic fibers such as rayon, polyolefin fibers, polyester fibers,bicomponent sheath-core fibers, multi-component binder fibers, and thelike. Synthetic cellulose fiber types include rayon in all its varietiesand other fibers derived from viscose or chemically-modified cellulose.In other embodiments, suitable synthetic fibers may include, but are notlimited to, rayon fibers, ethylene vinyl alcohol copolymer fibers,polyolefin fibers, polyesters, carbon fibers, silicon nitride fibers,and the like.

In addition, synthetic fibers may also be utilized in the presentinvention. The discussion herein regarding pulp fibers is understood toinclude synthetic fibers. Some suitable polymers that may be used toform the synthetic fibers include, but are not limited to: polyolefins,such as, polyethylene, polypropylene, polybutylene, and the like;polyesters, such as polyethylene terephthalate, poly(glycolic acid)(PGA), poly(lactic acid) (PLA), poly(β-malic acid) (PMLA),poly(ε-caprolactone) (PCL), poly(ρ-dioxanone) (PDS),poly(3-hydroxybutyrate) (PHB), and the like; polyamides, such as nylon,KEVLAR®, and the like, TEFLON®, and polyester nylons (EP). Synthetic ornatural cellulosic polymers, including but not limited to: cellulosicesters; cellulosic ethers; cellulosic nitrates; cellulosic acetates;cellulosic acetate butyrates; ethyl cellulose; regenerated celluloses,such as viscose, rayon, and the like; cotton; flax; hemp; and mixturesthereof may be used in embodiments disclosed herein.

Other polymers suitable for use in the fabric layer may includethermoplastic and non-thermoplastic polymers including natural andsynthetic polymers. In various embodiments, the fabric layer may includepolymers such as ethylene-vinyl acetate (EVA), ethylene/vinyl alcoholcopolymers, polystyrene, impact modified polystyrene, ABS,styrene/butadiene block copolymers and hydrogenated derivatives thereof(SBS and SEBS), and thermoplastic polyurethanes. Suitable polyolefinsmay include linear or low density polyethylene, polypropylene (includingatactic, isotactic, syndiotactic and impact modified versions thereof)and poly(4-methyl-1-pentene). Suitable styrenic polymers may includepolystyrene, rubber modified polystyrene (HIPS), styrene/acrylonitrilecopolymers (SAN), rubber modified SAN (ABS or AES) and styrene maleicanhydride copolymers. In other embodiments, the fabric layer may includemetal fibers, metal wire, metal mesh, metal belting or cording, or thelike.

In some embodiments, the fabric layer may have an average thickness inthe range from 0.05 mm to 5 mm (0.002 inches to 0.2 inches). In otherembodiments, the resilient layer may have an average thickness in therange from 0.1 mm to 3.8 mm (0.004 inches to 0.150 inches); from 0.25 mmto 3.2 mm (0.010 inches to 0.125 inches) in other embodiments; and from0.5 mm to 2.5 mm (0.020 inches to 0.10 inches) in yet other embodiments.

Foam Layer

In some embodiments, an optional foam layer may be disposed between thefabric layer and the substrate. In other embodiments, an optional foamlayer may be incorporated as one layer in a multi-layer resilient layer,as described above. In some embodiments, the foam layer may comprise anexpanded plastic, a polyolefin foam, a urethane foam, an ethylene-vinylacetate foam, or combinations thereof. In some embodiments, the foam maybe an open-cell foam, and in other embodiments, a closed-cell foam.

Adhesives

Adhesive materials, in some embodiments, include curable latex, urethaneor vinyl systems. Styrene butadiene rubbers (SBR), for example, are oneof the most common polymers used for latex adhesive backing materials.

In other embodiments, adhesives known as pressure sensitive adhesives(PSAs) and hot melt adhesives (HMAs) may be used. PSAs are a distinctcategory of adhesive, which, in dry (solvent free) form, are aggressiveand permanently tacky at room temperature and adhere to a variety ofsurfaces without the need of more than pressure. They do not requireactivation by water, solvent, or heat. In contrast, HMAs are typicallyapplied to a substrate while in its molten state and cooled to hardenthe adhesive layer. In some embodiments, HMAs with high heat resistanceand/or good cold resistance may be used. PSAs may be used in otherembodiments, and may provide many desirable characteristics such asremovability and ease of application. In yet other embodiments, curableadhesives (e.g., heat or light-cured) may be used, particularly wheresubstrates require substantial permanency and high strength adherence.

In other embodiments, a number of different polymers may be used as thebase component of adhesives in accordance with embodiments disclosedherein. For example, ethylene vinyl acetate (EVA) based polymers may beused. Other embodiments may use polyethylene-based polymers,polypropylene-based polymers, propylene-ethylene copolymers, amorphouspoly alpha-olefins, polyamides, block copolymers, and/or other polymersknown in the art. For example, ethylene ethyl acrylate (EEA),styrene-isoprene-styrene copolymers, styrene-butadiene-styrenecopolymers, as well as a number of other styrene copolymers (SEBS, SEPS,etc.), polyurethane, polyvinyl chloride, latex nitrile, acrylonitrilecopolymers, acrylics (including pure acrylics as well as styreneacrylics and vinyl acrylics), and polyisobutylene may be used. Inaddition, polymers such as ethylene butyl acrylate (EnBA) and epoxydizedpolybutadiene (PBE) may be used. This non-comprehensive list isrepresentative of the types of polymers that may be used in adhesivecompositions in accordance with embodiments disclosed herein. Thosehaving ordinary skill in the art will recognize that a number of othersuitable polymers and adhesives exist. In certain embodiments, it isanticipated an adhesive may be prepared without the use of a tackifieror with a minimal quantity of tackifier. An adhesive may also preparedwithout a wax, such as a blend of a polymer and a tackifying resin.Other embodiments may use an adhesive such as a gelled form ofcyano-acrylics, a slow-set urethane gel, a hot glue, a thixotropic glue.

In particular embodiments, the above described adhesives may be used tobond the resilient layer to the fabric layer. In other embodiments, theabove described adhesives may be used to bond the bed liner to thesurface of the substrate to be protected. In some embodiments, thefabric layer is bound to the substrate surface using an adhesive. Inother embodiments, where the fabric serves as an interior reinforcementof the resilient layer or is partially vulcanized into the resilientlayer, the resilient layer and/or the fabric layer may be bound to thesubstrate surface using an adhesive. In particular embodiments, theadhesive may adhere to a painted surface without requiring scarring,scuffing, or other damage of the painted surface.

In some embodiments, an adhesive bonding layer comprising a substrateintermediate two adhesive layers, such as double-sided tape for example,may be used to adhere the bed liner to the substrate to be protected. Insome embodiments, the intermediate substrate may include hook and looplayers.

Another adhesive that may be used includes a one-component adhesive formetal surfaces such as iron, zinc, copper, cadmium and their alloys thatwill cure upon contact with the metal surface, such as that disclosed inU.S. Pat. No. 5,096,962, for example. The adhesive composition includesan olefinically unsaturated monomer; an acidic compound; asulfonyl-containing compound; and a compound containing a transitionmetal. The adhesive composition may also optionally contain additionalpolymeric materials and will cure rapidly upon contact with a metalsurface to form an adhesive bond between metal surfaces. The adhesivecomposition avoids the use of halide-containing compounds which can beundesirable in certain applications.

In some embodiments, the adhesive used may permanently bind or adherethe liner to a substrate surface. In other embodiments, the adhesive mayremovably bind the liner to a substrate surface, allowing the liner tobe removed or partially removed from the substrate. Upon removal, insome embodiments, the adhesive may leave substantially no residue on thesubstrate surface.

In other embodiments, an adhesive may be used to bind the resilientlayer to the fabric layer. In certain embodiments, the resilient layeris removably bound to the fabric layer, allowing removal of at least aportion of the resilient layer, such as where it is desired to repair orreplace a portion of the resilient layer.

Additives

Embodiments of the bed liner or the individual components of the bedliner, including the cloth/fabric layer and the resilient layer, mayinclude various additives. Additionally, the adhesive used to affix theliner to a substrate surface to be protected may include variousadditives. For example, embodiments may include a wetting agent, fireretardants, surfactants, anti-static agents, antifoam agent, anti block,wax-dispersion, pigments, a neutralizing agent, a thickener, acompatibilizer, a brightener, a rheology modifier, a biocide, afungicide, reinforcing fibers, and other additives known to thoseskilled in the art. While optional for purposes of the presentinvention, other components may be highly advantageous for productstability during and after the manufacturing process. Other embodimentsmay include fillers, such as organic or inorganic particles, includingclays, talc, titanium dioxide, zeolites, powdered metals, organic orinorganic fibers, including carbon fibers, silicon nitride fibers, steelwire or mesh, and nylon or polyester cording, nano-sized particles,clays, and so forth; tackifiers, rosins, modified rosins, oil extenders,including paraffinic or napthelenic oils; and other natural andsynthetic polymers, including other polymers according to embodiments ofthe invention. Other embodiments may also contain organic or inorganicfillers or other additives such as starch, talc, calcium carbonate,glass fibers, polymeric fibers (including nylon, rayon, cotton,polyester, and polyaramide), metal fibers, flakes or particles,expandable layered silicates, phosphates or carbonates, such as clays,mica, silica, alumina, aluminosilicates or aluminophosphates, carbonwhiskers, carbon fibers, nanoparticles including nanotubes,wollastonite, graphite, zeolites, and ceramics, such as silicon carbide,silicon nitride or titania. Silane-based or other coupling agents mayalso be employed for better filler bonding.

Other embodiments may contain processing oils, plasticizers, andprocessing aids. Other embodiments may include carbon black, an additiveuseful for UV absorption and stabilizing properties. Various embodimentsmay also contain anti-ozonants or anti-oxidants that are known to arubber chemist of ordinary skill.

For providing additional stability against UV radiation, hindered aminelight stabilizers (HALS) and UV absorbers may be also used. Otherembodiments may include a heat stabilizer.

Other embodiments employ a crosslinking or curing agents, cureactivators, and accelerators. In other embodiments, vulcanizationretarders may also be used. In some embodiments, additives may alsoinclude perfumes, defoamers, algae inhibitors, dyes, pigments, orcoloring agents, such as colorants formed from titanium oxides, ironoxides, and the like, adhesion promoters, anti-microbiological andanti-fungus agents, a polyaniline or polypyrrole, non-skid agents,bubble-release compositions, flame retardants and halogen-free flameretardants, as well as slip and anti-block additives.

Liner

As described above with reference to FIG. 1, one embodiment of the liner10 described herein may include a fabric layer 14 and a resilient layer16. In various embodiments, liner 10 may include one or more fabriclayers 14 and one or more resilient layers 16. And, liner 10 may bedisposed on or adhesively conjoined to a surface of a substrate 12.

Liner 10, including each of the above described layers (resilient,fabric, and adhesive, as applicable) may have an overall averagethickness in the range from 0.1 mm to 50 mm (0.004 inches to 2.0inches). In other embodiments, the resilient layer may have an averagethickness in the range from 1 mm to 38 mm (0.040 inches to 1.5 inches);from 2.5 mm to 31.75 mm in other embodiments; and from 12 mm to 25 mm inyet other embodiments.

In some embodiments, at least a portion of the liner may be adhesivelybound to a substrate. In other embodiments, a majority of the liner maybe adhesively bound to a substrate. In other embodiments, the liner maybe form fitted or molded such that the liner and the substrate form anintimate fit, similar to a male/female connection. In this manner, theliner may form an intimate bond or fit with the substrate, minimizing oreliminating gaps, exposed areas, or places where water, dirt and debriscan accumulate under the liner, between liner component parts, orbetween the liner and the substrate. In some embodiments, as describedabove, the liner may be removably bound to a substrate.

Unitary Construction

In some embodiments, a liner may be constructed as a unitary part. Inother embodiments, a liner may be form fitted or molded to mate with adesired cavity or surface.

Referring now to FIGS. 2A-2D, one embodiment of a liner used to protecta truck bed 20 is illustrated. Truck bed 20 may include a floor 22,front wall 24, and two side walls 25. The floor 22 of the truck bed isoften contoured, including ridges 26, and an elevated portion 27corresponding to wheel wells 28. Tailgate 29 may be connected to truckbed 20, forming an open-top enclosure with truck bed 20 when closed.

A one-piece bed liner 30, as illustrated in FIG. 2B, may be form fittedto mate with the surface and contours of a truck bed 20. Bed liner 30may include a resilient layer 30R and a fabric layer 30F (see FIGS. 2Dand 2E), where the fabric layer may be configured to be bonded to thewear surface of a vehicle. Liner 30 may include a front portion 31,which may overlay and protect front wall 24. Liner 30 may also includesides 32, which may overly and protect side walls 25. Liner 30 may alsoinclude a bottom 33, overlaying and protecting floor 22. If desired, atailgate liner 30T may be used to protect tailgate 29, as illustrated inFIG. 2C.

In some embodiments, a bottom surface 34 of bottom 33 may be contouredto match the contours of truck bed 22, including a raised portion 34protecting elevated portion 27. In other embodiments, a bottom surface34 of bottom 33 may be contoured to mate with ridges 26, therebyminimizing any gaps that may promote collection of water, dirt, sand,etc. Contoured bottom surface 34 may also eliminate any shifting ofliner 30 during use, minimizing any abrasive contact that might occurbetween floor 22 and liner 30.

In addition to the contoured bottom surface 34, as illustrated in FIGS.2B and 2D, bottom 33 may also have a contoured top surface 35, asillustrated in FIG. 2E. In this manner, the liner 30 may provide aridged surface, similar to that of the underlying floor 22 of truck bed20, providing additional strength or resilience to the liner andfacilitating drainage from the lined bed.

In some embodiments, such as illustrated in FIGS. 2D and 2E, liner 30may include an upper lip 36, such that the contour of the sides 32 mateswith the structure of the side walls 25 of truck bed 20, engaging liprail 37 (as shown in FIG. 2A). In this manner, the recesses of sidewalls 25 of truck bed 20 are maintained, thereby maximizing the cargospace and intimately attaching liner 30 to bed 20. The lip 36 mayinclude a top portion 38 that overlays a top surface 39 of side walls25, a top surface 40 of front wall 24, or a top surface 41 of tailgate29.

Although illustrated generally in FIGS. 2B-2E, as mentioned above, theliner may be form-fitted or molded to mate with the contours of thetruck bed. In addition to the contours previously mentioned (ridges 26or lip rail 37, for example), those skilled in the art will recognizethat truck bed 20 may also include other contours, depressions, etc.,unique to a particular model or brand of truck. Liner 30 may be moldedto match only a few of the contours, a majority of the contours, or eachof the contours. Whereas embodiments where liner 30 matches most or allof the contours may provide for the maximum protection of truck bed 20,embodiments where liner 30 matches fewer contours may allow feweriterations of liner 30 to be produced. Those skilled in the art willrecognize that there are several ways to design a liner to protect abed, including over-the-rail, as shown in FIGS. 2D-2E, under-the-rail,etc.

Referring now to FIGS. 3A-3B, one embodiment of a liner used to protecta cabinet or cavity, such as a fire engine storage compartment, isillustrated. The liner 50, having a fabric layer 50A and a resilientlayer 50B, may be of unitary construction, form fitted or molded to matewith the surface and contours of the cavity 57.

In certain embodiments, it may be desired to install storage enhancingdevices 51 (brackets, shelves, holders, clasps, etc.) in a cavity 57,such that equipment or other items may be stored in an organized oraccessible fashion. A liner 50, in some embodiments, may be of athickness and hardness such that various storage devices 51 may beattached to liner 50 for hanging or holding equipment (such as, forexample, respiration equipment, tools, etc.)(not shown), whereinstallation of the devices 51 does not require damage to the substrate53. For example, a screw 54 may be used to hang bracket 55 on a backwall 56 of the storage compartment 57, wherein screw 56 penetrates to adepth equal to only a portion of the liner thickness t. In this manner,localized stress areas may be avoided, thus minimizing the potential forthe substrate 53 to begin to rust, and minimizing the avenues fordamaging moisture and chemicals to attack the substrate 53. In otherembodiments, a liner 48 may be positioned on door 59, such that liners50, 58 collectively protect the respective substrate surfaces fromchemical or impact damage due to the contents stored inside compartment57.

Multi-Component Construction

In some embodiments, the liner may be provided in multiple parts, asshown in FIGS. 4-6, 7A, and 7B, where each of the multiple parts mayinclude a resilient layer bonded to a fabric layer similar to that asillustrated in FIGS. 1, 2D and 2E, where the fabric layer is configuredto be adhered to the vehicle wear surface. Where the bed liner is formedfrom multiple pieces, in some embodiments, the multiple pieces may beinterconnected, overlaid, or mated, modularly forming a cohesiveprotective layer over the substrate. The overlying or mated portions maybe bound together using an adhesive in some embodiments, thus sealingthe boundary between the component liner pieces.

In other embodiments, the seams between the component pieces may befilled with a composition similar to the resilient layer or “welded”together, such as by heat sealing or by using a composition that willbind the two surfaces at the seams. For example, in some embodiments, anactivator compound, a vulcanizing agent, or a crosslinking agent may beapplied to the seams, causing the contacting portions of the seams tomeld together, sealing the seam areas. In other embodiments, heat may beapplied to the abutting edges of the component pieces to intimately bondthe component pieces.

Referring now to FIG. 4, one embodiment of a multi-component bed lineris illustrated. A bed liner may be formed from one or more componentpieces, as described above, where the embodiment of FIG. 4 provides abed liner formed from four component pieces. The multi-component liner70 includes front 72, left side 74, right side 76, and bottom 78. Acomponent piece may also be provided to cover the tailgate.

The surfaces of each component part that abut, mate with, or overlie anadjacent component part may be adhesively bound, sealed, filled, orwelded, as described above. For example, the bottom surface 80 of leftside 74 may be adhesively bound to the top surface 82 of bottom 78. Theinterior surface 84 of left side 74 may be adhesively bound to the sidesurface 86 of front 72. Likewise, the abutting or mating surfaces ofeach of the component parts may be bound.

Depending upon the size of the component pieces of the bed liner, it maybe beneficial, space-wise for storage and/or shipping, to form thecomponent parts in other configurations. For example, in otherembodiments, the multi-component bed liner may be formed where thecontour of the wheel well 87 is formed as part of side wall 88, asillustrated in FIG. 5. Bottom 89, in this embodiment, may thus be formedfrom a flat piece. In the embodiment illustrated in FIG. 6, a truck bedliner 90 may be formed from two component pieces. Left liner part 92 andright liner part 94 may be installed, where seams 96, 98 may be sealed,filled, or welded, as described above.

Where it is desired to have the component pieces overlay or matetogether, the component pieces may have seam edges contoured asillustrated in FIG. 7A or 7B. In the embodiment of FIG. 7A, angledsurface edges 100A and 100B may be adhesively bound together or sealedas described above. It should be understood that the contact area may bechanged by varying the angle of mating surfaces, etc. In the embodimentof FIG. 7B, one or more of the edges 101A/B, 102A/B, 103A/B may beadhesively bound together or sealed an overlapping joint as describedabove. Although illustrated and described in a limited number ofembodiments, those skilled in the art will recognize that otherconfigurations may be used to overlay or mate the component pieces.

Embodiments of the surface protective layer may also be useful inprotecting various sized surfaces, such as the cabinet described in FIG.3 above, where one or more component liner pieces may be custom fit tocover and protect the surface or a portion of the surface. For example,in one embodiment for the cabinet liner of FIG. 3, the cabinet may belined with two or more component liner pieces, such as where the back,sides, bottom, and top of the cabinet are each individually lined, andthe seams between the component liner pieces can be sealed, filled, orwelded, as described above.

The unitary or multi-component liners, as described above, may protect asubstrate against water or dirt accumulation, etc., protecting againstcorrosion, rust, abrasive damage, chemical attack, or deleteriousimpacts.

Forming the Liner

Embodiments of the liner described herein may be formed by injectionmolding, thermoforming, blow molding, spray molding, or any otherprocess used to form shaped articles. For example, in some embodiments,the liner or parts of a liner may be formed by spray coating a resilientlayer onto a fabric substrate. In some embodiments, the resilient layermay be sprayed, coated, or skim coated onto a fabric, forming aresilient layer having a uniform thickness on the substrate fabric.Where various shaped liners may be desired, the coated substrate may beshaped while the coating is curing, or, in other embodiments, the formedliner may subsequently be thermoformed or molded into a desired shape.In other embodiments, the coated substrate may be flexible, such thatthe liner may be shaped to conform to the dimensions of the underlyingsubstrate to be protected. In other embodiments, the composite materialmay be vulcanized in the mold.

In some embodiments, the liner may be formed in a mold. For example, inone embodiment, a liner, having a fabric layer or a reinforcing fabriclayer and a composite or polymer material as a resilient liner, may beformed by first placing the fabric in a mold tool. The mold tool maythen be closed and liquid polymer may be injected into the mold tool byinjection molding so as to bond or wholly encapsulate the fabric to theresilient layer, forming a liner having a desired shape. Where thefabric is used as a reinforcing layer, an inward force may be exerted onopposite faces of the fabric within the mold tool by fingers protrudinginwardly from inside faces of the mold tool, the fingers being operableto engage the reinforcing fabric when the mold tool closes. The fingersmay include inwardly projecting pegs which align with crossing points ofthe fabric to space the fabric from corresponding upper and lowerinternal surfaces of the mold tool and ensure that the reinforcingfabric is buried within the polymer or composite material which isinjected into the mold tool during the manufacturing process. Thepolymer or composite material is allowed to cure and then the liner maybe removed from the mold tool.

In other embodiments, the liner may be formed by first adhesivelybonding a fabric to a surface. The resilient layer may then be sprayedonto the fabric coated surface, where the fabric acts as a bridge,bonding the resilient layer to the surface. In some embodiments, theresilient layer may be removably bound to the fabric layer.

The liner may be formed, in some embodiments, from a vulcanized rubberbound to a fabric layer. In some embodiments, the fabric layer and thevulcanized rubber may be adhesively bound. In other embodiments, thefabric layer may be chemically bound, such as where the fabric layer andthe vulcanized rubber are at least partially crosslinked. The fabriclayer may serve as a bridge, allowing the vulcanized rubber to beremovably bound to a substrate to be protected.

Embossing/Printing

In some embodiments, the exposed surface of a liner may be printed withgraphics, such as indicia (indications of the manufacturer, for example)or aesthetic designs. In other embodiments, the liner may provide a slotor recessed area for placement of indicia, such as described in U.S.Pat. No. 6,076,879, for example. In other embodiments, letters orgraphics may be molded into the liner, for example, where the outersurface of a liner may contain raised lettering using a specializedmold, such as described in U.S. Pat. No. 5,308,133. In some embodiments,for example, the surface of the liner may include graphics, logos,pictures, decorative textures, and the like. Examples of liners havinggraphics or decorative textures are illustrated in FIGS. 8A and 8B.

In addition to printing, embossing, or custom molding, embodiments ofthe liner described herein may be marked to pinpoint drill targets fortie-down hardware. In other embodiments, the liner may be marked toidentify target locations of drain holes. In other embodiments, cutoutsfor the tie-down hardware locations and drain holes may be provided. Inyet other embodiments, the tie-down hardware locations and drain holesmay be removed (or pre-drilled) prior to shipment to a customer orretailer.

Advantageously, embodiments described herein may provide for a linerthat may protect a substrate from physical and/or chemical attack. Someembodiments of the liner described herein may provide for a liner whichforms an intimate bond with a substrate, minimizing or eliminating theaccumulation of dirt, debris, or water between the liner and thesubstrate. Other embodiments of the liner disclosed herein may providefor ease of installation, requiring minimal surface preparation. Otherembodiments of the liner disclosed herein may advantageously provide forremovably attaching the liner to a substrate, thereby facilitating anyneeded repairs or replacement, such as by use of a carpet knife, a hookknife, or other appropriate tools. Other embodiments described hereinmay provide for a hybrid bed liner that encompasses one or more of thefollowing aspects: easily installable, easily removable, excellentimpact and chemical resistance, minimal or no damage to the surface uponinstallation or removal, inexpensive, lightweight, sturdy, and heat andUV stability, among others.

While embodiments of the bed liner described herein have utility inpickups and vans, it should be understood, however, that it may also beapplied to other uses. For example, embodiments of the liner mayaccordingly be directed at providing a lined surface for buses, campers,motor homes, horse trailers, and the like. In addition, embodiments ofthe liner system may also be used in commercial and/or recreationalboats.

While the invention has been described with respect to a limited numberof embodiments, those skilled in the art, having benefit of thisdisclosure, will appreciate that other embodiments can be devised whichdo not depart from the scope of the invention as disclosed herein.Accordingly, the scope of the invention should be limited only by theattached claims.

All priority documents are herein fully incorporated by reference forall jurisdictions in which such incorporation is permitted. Further, alldocuments cited herein, including testing procedures, are herein fullyincorporated by reference for all jurisdictions in which suchincorporation is permitted to the extent such disclosure is consistentwith the description of the present invention.

1. A method to protect a vehicle wear surface, the method comprising:covering the vehicle wear surface with a plurality of liner sections;wherein each liner section comprises a resilient layer and a fabriclayer; adhering the fabric layer of each liner section to the vehiclewear surface; and joining adjacent liner sections together; wherein theadhering comprises adhesively bonding the plurality of liner sections tothe vehicle wear surface.
 2. The method of claim 1, wherein the adheringcomprises removably bonding the plurality of liner sections to thevehicle wear surface.
 3. The method of claim 1, wherein the adhering thefabric layer comprises forming a water-tight seal between the fabriclayer and the wear surface.
 4. The method of claim 1, wherein adjacentliner sections are configured to be bonded together to form a seal, andwherein the joining adjacent liner sections comprises forming a seal. 5.The method of claim 4, wherein the seal comprises angled surface edges,an overlapping joint, or combinations thereof.
 6. The method of claim 1,wherein each liner section is individually replaceable.
 7. The method ofclaim 1, wherein at least one of the plurality of liner sections iscontoured to form an intimate fit with the vehicle wear surface.
 8. Themethod of claim 1, wherein the vehicle wear surface comprises a pickuptruck bed.
 9. The method of claim 1, wherein the resilient layercomprises at least one of an acrylate polymer, a urethane polymer, avinyl rubber, a vinyl polymer, a polyolefin, a urethane rubber, avulcanized rubber, and a vulcanized urethane.
 10. The method of claim 1,wherein the fabric layer comprises at least one of natural fibers, metalfibers, and synthetic fibers.
 11. The method of claim 1, wherein thefabric layer has an average thickness from about 0.05 mm to about 5.0mm, and wherein the resilient layer has an average thickness from about0.1 mm to about 50.0 mm.
 12. The method of claim 1, wherein theresilient layer further comprises a reinforcing fabric layer.
 13. Themethod of claim 1, wherein the resilient layer has a durometer hardnessfrom about 10 Shore A to about 80 Shore D.
 14. The method of claim 1,further comprising disposing a graphic image on an outer surface of theresilient layer, molding a three dimensional image into the resilientlayer, or combinations thereof.
 15. The method of claim 1, wherein thefabric layer comprises: a first fabric layer bonded to the resilientlayer; and a second fabric layer bonded to the first fabric layer;wherein the adhering comprises adhering the second fabric layer to thewear surface of the vehicle.
 16. The method of claim 15, wherein thefirst fabric layer comprises a non-woven component comprising at leastone fibrous component and at least one polymeric component.
 17. Themethod of claim 16, wherein the at least one fibrous component comprisesat least one of cotton, acrylic, rayon, carbon, glass, nylon,thermoplastic, and bicomponent thermoplastic fibers.
 18. The method ofclaim 16, wherein the at least one polymeric component comprises atleast one of a polyethylene and a polypropylene.
 19. The method of claim1, wherein the fabric layer comprises a non-woven component comprisingat least one fibrous component and at least one polymeric component. 20.The method of claim 19, wherein the at least one fibrous componentcomprises at least one of cotton, acrylic, rayon, carbon, glass, nylon,thermoplastic, and bicomponent thermoplastic fibers.
 21. The method ofclaim 19, wherein the at least one polymeric component comprises atleast one of a polyethylene and a polypropylene.